Archives

The FBM237 contains eight 0-20 mA analog output channels. In situations where control system reliability is important, the FBM237 may have a redundant module installed. This permits all eight outputs to maintain operation in the presence of a single fault and during the time that the suspect module is removed and replaced. The 0-20 mA signals are electrically compatible with HART ®  field devices.

Module core functions and features

FBM237 is an 8-channel galvanized isolated 0~20mA analog output module. Its core design revolves around high reliability, flexibility, and compatibility. The key functions and features are as follows:

（1） Core functions

Multi scenario output capability:

Output range: 0~20.4mA DC (out of range design, compatible with standard 0~20mA actuators), single channel maximum load of 750 Ω, meeting the driving requirements of most industrial field equipment;

HART compatibility: The channel impedance meets the requirements of HART high impedance devices, can be connected to a HART handheld communicator (HHC), does not interfere with HART signal transmission, and supports intelligent device debugging and diagnosis.

Redundant deployment and failover:

Redundancy mode: Two FBM237s form a redundant pair and need to be installed in adjacent odd/even positions on the base (such as 1&2, 3&4), in conjunction with the redundant adapter RH916QD to achieve signal sharing;

Fault handling: Synchronize output commands through the AOUTR function block of Foxboro Evo control software. When a single module fails, automatically drive the fault channel current to 0mA. Normal modules seamlessly take over, and replacing faulty modules does not interrupt on-site output.

Safety and protection design:

Channel isolation: Each channel is Galvanically isolated from other channels and ground, withstanding 600V AC (1 minute) to avoid interference between channels and ground faults;

Current limit: The maximum output current of a single channel is about 25mA to prevent overload damage to the actuator;

Fail Safe: Supports “Hold” or “Fallback” modes, with a configurable fallback value of 0mA to avoid the risk of “high output failure”.

（2） Key characteristics

Environmental adaptability: Complies with ISA S71.04 G3 level harsh environmental standards, can withstand vibration (0.75g @ 5-500Hz), wide temperature range (working -20~70 ℃, storage -40~70 ℃), and is suitable for industrial high temperature and high dust scenes;

Hot plugging and maintenance: Module replacement does not require dismantling of on-site wiring, power or communication cables, and redundant module maintenance does not affect the operation of on-site equipment; Partial termination components (TA) with bypass sockets, supporting temporary output maintenance through bypass stations (such as P0900HJ);

Status indication: The front LED light provides real-time feedback on the communication status, power status, and channel faults of the module, making it easy to quickly locate problems;

Communication reliability: Connected to the fieldbus communication module (FCM) or control processor (FCP) through a 2 Mbps redundant fieldbus, supporting A/B dual path switching, and ensuring uninterrupted data transmission in case of single path failure.

Hardware parameters and technical specifications

（1） Output and precision parameters

Parameter category specific specifications

Channel configuration includes 8 independent channels, with each channel being Galvanically isolated (between channels, channel to ground)

Accuracy (including linearity) ± 0.05% range (within the range of 0.1~20mA), temperature coefficient ± 50 ppm/℃ (temperature changes have little impact on accuracy)

Maximum output delay of 30ms (meets the real-time requirements of most industrial controls)

Resolution of 13 bits (high output adjustment accuracy, supports fine control signal output)

Circuit power supply protection with independent current limitation and voltage regulation for each channel to avoid overload damage

The wiring distance depends on the compliant voltage (18V DC at 20.4mA), wire specifications, and equipment voltage drop, and supports a maximum of 30m cables

（2） Power supply and power consumption

Power input: 24V DC (redundant mode, allowable range+5%/-10%, i.e. 21.6-26.4V DC), requires independent redundant power supply;

Power consumption: Maximum 7W (running) at 24V DC, maximum heat dissipation of 5W, reserved heat dissipation space is required to avoid module overheating.

（3） Physical and environmental parameters

Parameter category specification requirements

Dimensions (module) height 102mm (including installation ears 114mm) x width 45mm x depth 104mm, single slot design

The weight module weighs approximately 284g (10oz); TA approximately 181-249g (0.40-0.55lb, depending on terminal type)

Working environment temperature -20~70 ℃, humidity 5%~95% (non condensing), altitude -300~3000m

Storage environment temperature -40~70 ℃, humidity 5%~95% (no condensation), altitude -300~12000m

The pollution level complies with EIA 364-65 Class III and is suitable for harsh environments with ISA S71.04 G3 level (high dust, high humidity)

Installation and Termination Component (TA) Configuration

FBM237 needs to be used in conjunction with a dedicated base, termination assembly (TA), and cables. Installation and wiring must follow strict specifications, with the following core requirements:

（1） Base and installation

Base type:

Modular base: Supports DIN rail (32mm/35mm) or 19 inch rack installation, with a maximum capacity of 8 FBM modules per base;

Redundant installation: Redundant modules need to be fixed in adjacent odd/even positions, connected to the base terminals through the redundant adapter RH916QD, to achieve two modules sharing one TA signal interface.

Installation specifications:

Heat dissipation space: Reserve ≥ 25mm space on each side of the module to avoid the influence of adjacent devices on heat dissipation;

Grounding requirements: Galvanized yellow chromium steel DIN rails are preferred for the base to ensure reliable grounding, and aluminum/plastic rails are prohibited (which may cause poor grounding).

（2） Termination Component (TA) Selection

TA is a key component connecting FBM237 with on-site actuators, providing signal switching and bypass maintenance functions. It needs to be selected according to the scenario, and the specific model and adaptation scenario are as follows:

TA model core function adaptation scenario authentication type

RH916YE (main TA) 8-channel signal transfer, no bypass function, normal scenario (no online maintenance required) Type 1/2 (compatible with hazardous areas)

RH917QZ (main TA) 8-channel with bypass socket, supporting bypass station access to critical scenarios (requiring online maintenance, such as chemical reaction kettle) Type 4/5 (ordinary area+Class 2 circuit)

TA connection: TA connects to the base through a Type 1 cable (25 pin D-sub interface), with a maximum cable length of 30m, supporting 2 materials:

P/PVC: polyurethane outer layer+PVC insulation, temperature range -20~80 ℃, suitable for ordinary industrial environments;

LSZH (Low Smoke Zero Halogen): Low smoke zero halogen release at high temperatures, suitable for enclosed environments such as ships and subways, with a temperature range of -40~105 ℃;

Wiring specifications: TA supports solid/multi strand wires of 0.2~4mm ² (24~12 AWG), and multi strand wires with wire ears should be 0.2~2.5mm ² (with or without plastic sleeves), with terminal torque in accordance with manufacturer specifications.

Compliance certification and security requirements

（1） Core certification

The FBM237 module and its supporting TA comply with global safety, electromagnetic compatibility, and environmental standards in multiple regions, with the following core certifications:

Specific standards and levels for certification categories

Hazardous Area Certification North America: UL/UL-C Class I Division 2 Groups A-D, Temperature Code T4;

Europe: ATEX 2014/34/EU II 3 G Ex nA IIC T4 (DEMKO certification, except RH917QZ);

International: Compliant with IECEx standards and suitable for Zone 2 hazardous areas

Electromagnetic Compatibility (EMC) EU EMC Directive 2014/30/EU, compliant with EN 61326-1:2013 Class A (Emission and Immunity in Industrial Environments)

Low Voltage Safety EU Low Voltage Directive 2014/35/EU, communication circuits comply with UL Class 2 standards (NFPA 70 Article 725, CSA C22.1 Section 16)

Environmental compliance complies with the EU RoHS 2011/65/EU directive, restricting the use of harmful substances such as lead and mercury

Ship certification ABS type approval, French Classification Society (BV) EC31 environmental category certification, applicable to ship automation systems

（2） Safety operation requirements

Electrical safety:

Isolation restriction: Although the module can withstand 600V AC, it is prohibited to connect to excessive voltage (such as 220V AC) for a long time to avoid insulation damage;

Wiring specifications: On site wiring should distinguish between positive and negative poles. In redundancy mode, ensure that the two modules have independent power supplies to prevent redundancy failure caused by single point power failure.

Dangerous area operation:

Shell requirements: It must be installed in a certified shell with a protection level of IP54 or above, and the shell must be opened with tools to prevent unauthorized operation;

Maintenance process: Power off or confirm that the area is in a non hazardous environment before connecting/disconnecting cables. Redundant module replacement should be carried out after the faulty module is powered off.

Upgrade and compatibility instructions

FBM237 is mainly used to replace the Foxboro 100 series FBM37 analog output module. When upgrading, the following compatibility points should be noted:

Hardware replacement: A single FBM237 can directly replace one FBM37, and on-site wiring can be reused in two ways:

Direct adaptation: Use the documentation to specify the TA (such as RH916YE) and rewire it to the TA terminal;

Adapter reuse: Connect the terminated component adapter (TAA, refer to PSS 31H-2W4) directly to the original FBM37 wiring without rewiring.

Software adaptation:

Should be paired with Foxboro Evo control software v8. x+or Control Core Services v9.0+, supporting AOUTR redundant function block configuration;

The failure safety parameters need to be pre-set in the software (such as a fallback current of 0mA and a fault delay time) to ensure that the actuator is in a safe state in case of a fault.

Core functions and features of the module

FBM217 is a 32 channel discrete input module designed specifically for industrial environments, supporting multi voltage level signal acquisition and high reliability operation. Its core functions and features are as follows:

（1） Core functions

Multi voltage signal support: covering low, medium, and high voltage inputs, including:

Low voltage: 15~60V DC (voltage monitoring or contact detection);

Medium voltage: 120V AC/125V DC (logic 0:0~20V AC/DC, logic 1:80~132V AC/75~150V DC);

High voltage: 240V AC (logic 0:0~40V AC, logic 1:164~264V AC).

Redundancy deployment capability: Supports single module or redundant paired deployment (2 FBM217s need to be installed in adjacent odd/even positions on the base, with the redundant adapter RH926ZY). In redundancy mode, the input signal quality is verified through the CINR function block of Foxboro Evo control software, and the optimal signal is automatically selected.

Event Sequence (SOE) Function: In conjunction with I/A Series v8. x and above software or Control Core Services v9.0+, supports event collection, storage, and reporting, with optional GPS time synchronization (accuracy up to 1ms); The old version software (before v8. x) needs to be implemented through the ECB6/EVENT block, with an accuracy of 1 second and no cross processor synchronization.

Signal conditioning and protection: relying on termination components (TAs) to achieve optical isolation, current limitation, and voltage attenuation. Some TAs support external excitation power supply access without the need for additional on-site circuit protection equipment (such as fuses).

（2） Key characteristics

Environmental adaptability: Complies with ISA S71.04 G3 level harsh environmental standards, can withstand vibration (0.75 m/S ² @ 5-500Hz), wide temperature range (working -20~70 ℃, storage -40~70 ℃);

Hot swappable design: When replacing modules, there is no need to remove on-site wiring, power or communication cables. The replacement of redundant modules does not affect the on-site signal acquisition of normal modules;

Status indication: The front LED light provides real-time feedback on the operating status of the module (such as fault, ready) and the discrete status of a single input channel, facilitating quick diagnosis;

Communication reliability: Connected to the Fieldbus Communication Module (FCM) or Control Processor (FCP) via a 2 Mbps module fieldbus, supporting A/B dual path communication and automatic switching in case of single path failure.

Hardware parameters and technical specifications

（1） Input and electrical parameters

Parameter category specific specifications

Channel configuration with 32 isolated channels (isolation level dependent on TA, some TAs support channel level isolation)

Typical 2.2mA at 30V DC input current; maximum 2.8mA at high voltage (240V AC) (logic 1 state)

Source resistance limit logic 1 (15V DC) ≤ 1k Ω; logic 0 (30V DC) ≥ 100k Ω

The filtering/debounce time can be configured (no filtering, 4ms, 8ms, 16ms, 32ms, firmware v1.25H+required)

Maximum pulse counting rate 250Hz

The combination of isolation voltage module and TA can withstand 600V AC (1 minute, group isolation channel to ground)

（2） Power supply and power consumption

Power input: 24V DC (redundant mode, allowable range+5%/-10%, i.e. 21.6-26.4V DC);

Power consumption: maximum 3W at 24V DC (operation), maximum heat dissipation 5W;

Power protection: Supports redundant independent DC power supply access to enhance power supply reliability.

（3） Physical and environmental parameters

Parameter category specification requirements

Dimensions (module) Height 102mm (including installation ears 114mm) x Width 45mm x Depth 104mm

The weight module weighs approximately 284g (10oz); TA approximately 420-454g (0.93-1.0lb)

Working environment temperature -20~70 ℃, humidity 5%~95% (non condensing), altitude -300~3000m

Storage environment temperature -40~70 ℃, humidity 5%~95% (no condensation), altitude -300~12000m

The pollution level complies with EIA 364-65 Class III and is suitable for harsh environments of ISA S71.04 G3 level

Installation and Termination Component (TA) Configuration

FBM217 needs to be used in conjunction with a dedicated base and termination assembly (TA), and installation and wiring must follow strict specifications. The core requirements are as follows:

（1） Base and installation

Base type: Modular base (DIN rail or 19 inch rack mounted), with a maximum capacity of 4 or 8 FBM modules per base;

Redundant modules need to be installed in adjacent odd/even positions (such as 1&2, 3&4) and connected through redundant adapter RH926ZY;

Support 100 series conversion installation structure (refer to PSS 31H-2W8) for easy upgrading of old systems.

Installation specifications:

DIN rail: Supports 32mm/35mm specifications, with priority given to galvanized yellow chromium steel material (ensuring good grounding), fixed at a spacing of approximately 200mm;

Panel installation: Use M4 or # 8 screws and reserve heat dissipation space (≥ 25mm on each side of the module).

（2） Termination Component (TA) Selection

TA is the core component connecting FBM217 with on-site signals, providing signal conditioning, isolation, and power distribution functions. It needs to be selected according to the input signal type. Common TA and adaptation scenarios are as follows:

TA model adaptation signal type isolation level certification type

RH916CA (main TA) 30V DC voltage monitoring, 32 channel group isolation Type 1/2/4

RH916XZ (main TA) 24V DC contact detection, 32 channel group isolation Type 1/2/4

RH916YA (main TA) 132V AC/150V DC voltage monitoring, 32 channel isolation Type 1/4

RH916PU (main TA) 240V AC voltage monitoring, 32 channel isolation Type 1

RH924HB (Extended TA) replaces FBM12A/B expansion module, 16 channel group isolation Type 1/2/4

RH924HD (Extended TA) replaces FBM13 expansion module, 16 channel isolation Type 1/4

TA connection: The main TA is connected to the base through a Type 4 cable (37 pin D-sub interface), and the extended TA is cascaded through a Type 6 cable (main TA 25 pin → extended TA 37 pin), with a maximum cable length of 30m, supporting P/PVC or LSZH materials (LSZH is suitable for low smoke and halogen-free scenarios);

Upgrade adaptation: When replacing the 100 series FBM (such as FBM07A/B, FBM08, FBM20), it is necessary to match the corresponding main TA+extended TA (such as replacing FBM07A with RH924HA main TA+RH924HB extended TA).

Compliance certification and security requirements

（1） Core certification

The FBM217 module and its supporting TA comply with global safety and electromagnetic compatibility standards in multiple regions, with the following core certifications:

Specific standards and levels for certification categories

Hazardous Area Certification North America: UL/UL-C Class I Division 2 Groups A-D, Temperature Code T4;

Europe: ATEX 2014/34/EU II 3 G Ex nA IIC T4 (DEMKO certification);

International: IECEx Ex nA IIC T4, certificate number refers to relevant TA documents

Electromagnetic compatibility (EMC) complies with EN 61326-1:2013 Class A (Emission and Immunity in Industrial Environments), EU EMC Directive 2014/30/EU

Low voltage safety EU Low Voltage Directive 2014/35/EU, in compliance with EN 61131-2 standard; UL Class 2 Circuit (Communication Circuit)

Environmental compliance complies with the EU RoHS 2011/65/EU directive, restricting the use of hazardous substances

Ship certification ABS type approval, French Classification Society (BV) EC31 environmental category certification

（2） Safety operation requirements

Electrical safety:

On site wiring must comply with Class 2 circuit restrictions (60V DC/30V AC, below 100VA), and high voltage TA must avoid long-term overvoltage operation (such as prohibiting the connection of signals above 300V AC to 240V AC modules);

Grounding requirements: The base is grounded through a DIN rail, and the use of aluminum/plastic rails is prohibited (which may cause poor grounding). The TA isolation channel needs to be grounded separately.

Dangerous area operation:

It needs to be installed in a certified enclosure with a protection level of IP54 or higher, and the enclosure needs to be opened with tools;

Before connecting/disconnecting cables, power off or confirm that the area is in a non hazardous environment. Replacement of non certified components is prohibited.

Upgrade and compatibility instructions

FBM217 is mainly used to replace Foxboro 100 series discrete input FBM modules. When upgrading, the following compatibility points should be noted:

Hardware replacement: A single FBM217 can replace one 100 series main FBM (such as FBM07A/B, FBM08)+one extended FBM (such as FBM12, FBM13), which needs to be matched with the corresponding functional main TA and extended TA (refer to the document “TA Selection Table for Migration”);

Software adaptation:

New system: requires Studio 5000 or Foxboro Evo control software v8. x+, supporting redundant CINR blocks and GPS SOE synchronization;

Old system: 100 series upgrade can use termination component adapter (TAA, refer to PSS 31H-2W4) without rewiring;

Cable Reuse: Some 100 series on-site cables can be adapted to FBM217 through TAA, but the voltage level and TA compatibility need to be confirmed.

I/O module classification and core types

The 1756 series I/O modules can be divided into four categories based on their functions: digital I/O, analog I/O, HART interface module, and special function module. Each type of module is distinguished by its core characteristics through model suffixes (such as “D” representing diagnostic function, “E” representing electronic fuse, and “I” representing isolation). The specific classification and typical models are as follows:

（1） Digital I/O module

Covering AC/DC power supply, supporting enhanced functions such as diagnosis, electronic melting, isolation, etc., suitable for switch signal acquisition and actuator control.

Module type, typical model, core characteristics

AC digital input 1756-IA8D, 1756-IA16I 120V/240V AC power supply, 1756-IA8D includes point level diagnosis, 1756-IA16I supports channel independent isolation

DC digital input 1756-IB16D, 1756-IB16I 12/24V DC sinking/tracing input, 1756-IB16D supports wire breakage detection, 1756-IB16I is fully isolated

AC digital output 1756-OA8E, 1756-OA16I 120/240V AC output, 1756-OA8E with electronic fuse, 1756-OA16I channel independent isolation

DC digital output 1756-OB8EI, 1756-OB16D 12/24V DC output, 1756-OB8EI includes electronic fuse+isolation, 1756-OB16D supports fault diagnosis

Common parameters: Most digital quantity modules have a working temperature range of 0-60 ℃, a storage temperature of -40… 85 ℃, anti vibration (2g @ 10… 500Hz), anti impact (30g working/50g storage), and EMC compliance with CISPR 11 Class A standards.

（2） Analog quantity I/O module

Used for high-precision acquisition and output of voltage and current signals, supporting multiple ranges and isolation designs, suitable for signal processing of sensors such as pressure and flow sensors.

Module type, typical model, core characteristics

Analog input 1756-IF8, 1756-IF16 support ± 10V/0… 10V/0… 20mA range, 1756-IF16 includes 16 channels, Sigma Delta conversion technology

Analog output 1756-OF4, 1756-OF8I output range ± 10V/0… 20mA, 1756-OF8I supports channel isolation, accuracy 0.1% range

High speed analog I/O 1756-IF4FXOF2F with 4 high-speed inputs and 2 high-speed outputs, sampling time of 300 μ s, supporting floating-point/integer data formats

Accuracy characteristics: The calibration accuracy of most analog modules is better than 0.1% of the range (25 ℃), with a temperature drift coefficient of 15-50 ppm/℃, input impedance voltage type>1M Ω, and current type around 249 Ω.

（3） Temperature measurement module

Specially designed for RTD (resistance temperature detector) and thermocouple, supporting multiple types of sensors and temperature ranges, suitable for industrial process temperature monitoring.

Module type, typical model, core characteristics

The RTD input modules 1756-IR6I and 1756-IR12 support RTDs such as Pt100/Pt1000/Ni120/Cu10. The 1756-IR12 includes 12 channels with a range of -200… 870 ℃

Thermocouple input modules 1756-IT6I and 1756-IT16 support thermocouples such as B/E/J/K/R/S/T. 1756-IT16 includes 16 channels and integrates cold junction compensation (CJC)

Mixed temperature module 1756-IRT8I 8-channel configurable RTD/thermocouple, supports ITS-90 linearization, isolation voltage 250V continuous

Temperature range: Thermocouple module covers -270… 2320 ℃ (such as Type C thermocouples), RTD module covers -200… 870 ℃ (Pt100), cold end compensation accuracy ± 0.3 ℃.

（4） HART interface and special modules

Support HART protocol communication and special industrial scenarios, such as safety interlocking, high-speed counting, etc.

Module type, typical model, core characteristics

The HART input modules 1756-IF8H and 1756-IF16H support the HART protocol, 8/16 channel current input, are compatible with HART smart sensors, and have an isolation design

High speed counting module 1756-HSC high-speed pulse counting and position detection, supports multiple counting modes, suitable for motor speed and encoder signal acquisition

Safety module 1756-LSC8XIB8I safety logic control, with 8 inputs and 8 outputs, meets safety standards and is suitable for interlocking in hazardous scenarios

Common core technologies and installation requirements

（1） Electrical and mechanical commonalities

Power supply and power consumption: All modules need to be powered from the rack backplane, with a 5.1V DC current consumption of 100… 400mA (depending on the module type), a 24V DC current consumption of 2… 150mA, and a total backplane power of 0.5… 10W;

Isolation and protection: The isolation voltage is mostly 250V continuous (basic insulation), and some modules (such as 1756-OB8I) support enhanced isolation. The terminal block supports user-defined mechanical key control to prevent misconnection;

Response time: The input delay of the digital module is 0.2… 10ms (configurable filtering), the sampling time of the analog module is 1ms… 50ms, and the minimum sampling time of the high-speed module (such as 1756-IF4FXOF2F) is 300 μ s.

（2） Environmental and installation requirements

Environmental parameter requirement standards

Working temperature: 0… 60 ℃ (some modules can be extended to -20… 70 ℃, please refer to the specific model)

Relative humidity 5… 95% non condensing (IEC 60068-2-30)

Electromagnetic compatibility (EMC) anti ESD: 6kV contact/8kV air discharge; Anti radiation interference: 10V/m (80… 2000MHz)

Installation method: Rack mounted, single slot width (some special modules occupy 2 slots), supports DIN rail or wall mounted rack

Compliance certification and application scenarios

（1） Global Compliance Certification

All 1756 series modules have passed multi regional safety and electromagnetic compatibility certification, with core certifications including:

North America: UL Listed (UL Document E65584), CSA Certified (Class I Division 2 Hazardous Area);

Europe: CE certification (compliant with EN 61326-1, EN 61000-6-2/4), ATEX certification (II 3 G Ex nA IIC T4 Gc);

Other: FM hazardous area certification, KC Korean radio certification, C-Tick Australian electromagnetic certification.

（2） Typical application industries

Module based high reliability and flexibility, widely used in:

Process industry: petroleum and natural gas, chemical industry, cement (analog quantity+HART module monitoring pressure/flow);

Discrete manufacturing: automobiles, food and beverage (digital quantity module controls motors/valves);

Energy and Transportation: Power Plants, Ships (Temperature Module Monitoring Equipment Temperature, Safety Module Interlocking).

Key selection and usage tips

Model identification: quick judgment function through model suffix, such as “D”=diagnosis, “E”=electronic fuse, “I”=isolation “H”=HART；

Terminal block selection: Select RTB based on the number of module channels and wiring requirements. For example, 1756-TBCH is suitable for multi-channel isolation modules, while 1756-TBNH is suitable for ordinary digital modules;

Calibration cycle: It is recommended to calibrate the analog and temperature modules every 6-12 months to ensure accuracy;

Dangerous area use: For Class I Division 2 areas, modules with corresponding certifications (such as CSA LR69960C, FM certification) should be selected to avoid direct use of non certified modules.

System and hardware requirements

（1） System requirements

Category specific requirements

PC hardware should have at least an Intel Pentium 4 processor, 512MB of memory, and 100MB of available hard disk space; Suggest a 17 inch/19 inch (1280 × 1024 and above resolution) monitor; CD/DVD drive, power cable, Ethernet cable, keyboard and mouse required

The PAC/PLC power ESR2 module consumes 5VDC 850mA and 24VDC 1.75mA; The SR4 module consumes 5VDC 1004mA and 24VDC 1.75mA. Please refer to the CLX 5000 modular installation and operation manual to calculate the total power load

The PC operating system supports Windows XP, Vista, 7, and 8

Other requirements: 1. Support for Rockwell Automation RSLogix 5000 Additional Instructions (AOI) requires RSLogix 5000 V16 or above, module firmware must be 2.10.2 or above (general configuration file) or 2.12.1 or above (additional configuration file/AOP), BCMS software must be 1.9 or above

2. Support for RSLogix 5000 additional configuration files (AOP) requires RSLogix 5000 V15 or above version, module firmware 2.3.0 or above, BCMS software 1.7.0 or above, and AOP only supports maximum input/output/status INT size (250, 248, 250), small size requires 1756 universal configuration file

（2） Hardware and Packaging

package contents

The module model includes items and quantities

SST-ESR2-CLX-RLL 1 communication module, 2 RJ45 to DB9 serial cable adapters, 1 Windows system installation CD (including BCMS software), PDF versions of the CD including user guide, Siemens Industrial Ethernet protocol guide, Modbus TCP/serial protocol guide

SST-SR4-CLX-RLL 1 communication module, 4 RJ45 to DB9 serial cable adapters, 1 Windows system installation CD (including BCMS software), CD containing user guide, Modbus serial protocol guide PDF version (Siemens Industrial Ethernet, Modbus TCP protocol guide PDF included but not applicable)

Hardware features: All include status LEDs (COMM, SYS, OK, indicating communication/connection/initialization status respectively), RJ45 serial interface (connecting RS232/422/485 devices with transmit/receive indicator lights), USB configuration port (downloading configuration/upgrading firmware); ESR2 additionally includes an RJ45 Ethernet interface (connected to industrial networks with activity/link indicator lights), while SR4 does not have an Ethernet interface; All have self-locking tongue fixing modules, and LCD displays firmware version, connection status, IP address, and other information.

Core functions and software

（1） Core functions of the product

Differences and Commonalities of Modules

Function SST-ESR2-CLX-RLL SST-SR4-CLX-RLL

Number of interfaces: 1 Ethernet port+2 serial ports+4 serial ports

Supports protocol Modbus TCP/serial, Siemens S5/S7 communication only Modbus serial communication

Common feature 1. Supports two database addressing modes: default and extended. In default mode, 0-699 address mapping is used for CLX input/output/status tables. In extended mode, 30K address mapping can be customized

2. Support cyclic function (read and write data periodically, up to 255 per channel), which can be dynamically triggered

3. Supports AOI/AOP and CIP messaging (reading and writing databases, triggering cyclic functions)

4. Supports remote rack configuration, Listen Only mode, and can be configured as client/server (master-slave) mode

Protocol support details: Modbus supports function codes such as FC3 (read multiple registers), FC6 (write single registers), FC16 (write multiple registers), etc; Siemens S5/S7 supports reading and writing of variable types such as ABx/AWx, EBx/EWx, MBx/MWx, DBx.DBx, etc.

（2） Software and Tools

BCMS software: Brad Communication ™  The SST backplane communication module software includes Configuration Manager (managing configuration files, such as creating/uploading/downloading configurations, modifying IP addresses), Console (configuring ports/protocols/devices, creating cyclic functions, including tools such as PCInit/ReadWait/WriteWait). After installation, the configuration files, AOI files, and firmware are stored in the corresponding system paths (Windows XP/7 paths differ).

Diagnostic and management tools: including Visucyc (monitoring cyclic function status), Network Diagnostic (diagnosing ESR2 Ethernet activity), Firmware Installer (upgrading firmware), etc., supporting module connection through USB, RSLinx, TCP/IP, and other methods.

Configuration and Operation Guide

（1） Quick configuration process

Backplane communication verification: The module supports live plugging and unplugging (RIPP). During installation, align the guide rail and insert it into the rack. Configure the EtherNet/IP driver through RSLinx and browse the rack to confirm that the module is recognized (ESR2 product code 53, SR4 product code 54).

Module configuration (RSLogix 5000)

AOP configuration (recommended): You need to install the AOP installation package first, add the SST-ESR2/SR4-CLX-RLL module to RSLogix 5000, configure the slot, connection type (Output w/Status/Sten Only), RPI (5-750ms), program mode output status (such as Zero CyclicRuns), and ensure that the configuration name is consistent with the module.

General configuration file: Add 1756-MODULE, set communication format (such as Data INT with Status), assembly instance and size for input/output/configuration/status (such as input instance 1, size 250).

Initialization and Address Mode Switching: Initialize the module through Console’s PCInit; The database address mode can be switched in Configuration Manager. The default mode maps the CLX table from 0-699, and the extended mode allows customization of input/output/status addresses and lengths (firmware 2.10.2 or above is required).

（2） Typical Configuration Example

Modbus TCP configuration: ESR2 can be configured as a server (select Modbus TCP protocol), client (add Modbus device, set IP address), or both client and server, creating cyclic functions (set cycle, data volume, device address, database offset).

Modbus serial configuration: Both modules can be configured as slaves (select Modbus RTU/ASCII Slave) or hosts (add Modbus slave devices, set slave numbers), supporting multi-channel master-slave hybrid configuration.

Siemens S7/S5 configuration: Only supported by ESR2, can be configured as a server/client, adding devices such as S7 300/400/1200, creating cyclic functions to read and write variables such as DBx.DWx.

Compliance and Support

（1） Compliance certification

Compliant with CE/EU, RoHS, FM (Class 1 Div 2 Groups A-D), FCC, Korean certification, RINA certification, electrical safety complies with EN 61010-1, EMC complies with EN 61000-6-2/4.

（2） Warranty and Support

Warranty: According to Molex standard warranty terms, please refer to Appendix F of the document for details.

Technical Support: You can contact Molex Canada at 216 Bathurst Drive, Waterloo, Ontario, Canada N2V 2L7; Phone: 1.775.782.3611 or 1.800.227.5514 (US only), or visit the official website Bently.com for patent information and the latest documents.

Basic product information

（1） Core identification and specifications

Core parameters: rated power 11.0kW, input current 25A, product model ACS880-01-025A-3, product ID 3AUA0000107992, EAN code 6438177557197.

Production and ordering: The country of origin is Finland (FI) and Saudi Arabia (SA), with customs tariff code 85044084, and it belongs to customized production (Made To Order); The minimum order quantity is 1 piece, the order multiple is 1 piece, and the sales measurement unit is “piece”, not just the quoted product.

Packaging and dimensions: The net weight of the product is 8.4kg, and the net dimensions (depth/length x height x width) are 249mm x 409mm x 155mm; the first level packaging dimensions (depth/length x height x width) are 574mm x 304mm x 256mm, with one piece per box and a total volume of 15.785dm ³.

Application and installation features

（1） Applicable scenarios

Industry adaptation: customized for industries such as oil and gas, mining, metallurgy, chemical, cement, power plants, material handling, pulp and paper, sawmills, ships, water supply and drainage, food and beverage, automobiles, etc.

Load type: can control various equipment such as cranes, extruders, winches, coilers, conveyors, mixers, compressors, centrifuges, test benches, elevators, pumps, fans, etc.

（2） Installation and Protection

Installation method: The standard is wall mounted installation, and installation inside the cabinet is optional.

Protection level: The shell protection level is IP21, and the NEMA protection type is Type 1, suitable for most industrial environments; The maximum working environment temperature is 40 ℃, the sound pressure level is 59dB (A), and the operating noise is relatively low.

Key technical parameters

（1） Electrical input and output

Category parameter details

Input parameters: 3-phase power supply, frequency 50/60Hz, input voltage 380-415V

The output current (under different operating conditions) is typically 25A, 24A for light overload, and 17A for heavy load

The output power for both regular and light overload use is 11kW, with an apparent output power of 17kV · A

Efficiency related efficiency level IE2, standby loss 23W; efficiency varies under different operating conditions (such as 95.6% efficiency at 50Hz/100% current)

（2） Communication and Interface

Communication Protocol: Supports MODBUS、DeviceNet、PROFIBUS、PROFIsafe、CAN、EtherNet/IP、PROFINET IO、TCP/IP  And other bus systems.

Hardware interface: including 1 RS-485 interface, 1 USB interface, and 6 other interfaces; No industrial Ethernet PROFINET、RS-232、RS-422、 Parallel interface.

Signal ports: 2 analog inputs, 2 analog outputs, 6 digital inputs/5 digital outputs; With control unit, no optical interface, supports PC connection.

（3） Efficiency details (compliant with IEC 61800-9-2 standard)

Operating conditions (frequency/current) absolute loss relative loss efficiency

0Hz / 25% 126W 0.7% 87.9%

0Hz / 50% 168W 1.0% 91.3%

0Hz / 100% 301W 1.7% 92.2%

50Hz / 25% 135W 0.8% 93.4%

50Hz / 50% 185W 1.1% 95.2%

50Hz / 100% 342W 2.0% 95.6%

90Hz / 50% 203W 1.2% 97.0%

90Hz / 100% 412W 2.4% 97.0%

Classification and Environmental Information

（1） Product classification

Series affiliation: ACS880 series, product type is low-voltage AC frequency converter, specifically classified as “frequency converter → low-voltage AC frequency converter → industrial frequency converter → ACS880 single machine frequency converter → ACS880-01 wall mounted single machine frequency converter”.

Standard classification: ETIM 7 is classified as EC001857 (≤ 1kV frequency converter), UNSPSC is classified as 39122001.

（2） Environmental compliance

WEEE category: 5 categories (small equipment, with external dimensions not exceeding 50cm).

SCIP code: Finland (FI) code 090be974-b30f-4eaa-b924-275d6a7f6686; Belgium (BE), the Netherlands (NL), Denmark (DK), Spain (ES), Portugal (PT), Estonia (EE) and other countries each have their own simplified SCIP codes.

Module foundation and core characteristics

SKiiP 1213 GB123-2DL V3 is a SKiiP under SEMIKRON ® The 3-series 2-in-1 integrated intelligent power system has high integration and industrial grade reliability, with the following core features:

Core technology: Built in SKiiP technology, using trench insulated gate bipolar transistors (Trench IGBTs) and CAL HD diode technology, balancing efficient switching and low loss;

Integrated components: Equipped with current sensors, temperature sensors, and heat sinks, reducing the need for external accessories and simplifying installation;

Compliance certification: UL certified, document number E63532, meets industrial safety standards.

Typical application scenarios cover fields with high requirements for power control, such as renewable energy, traction systems, elevators, and industrial transmissions (note: MKP capacitors that are compatible with each terminal need to be used).

Key electrical parameters (unless otherwise specified, ambient temperature Ts=25 ℃)

（1） Absolute maximum rated value

Category parameter symbol condition description numerical unit

System VCC working DC link voltage 900 V

Visol DC for 1 second, main terminal to heat sink 4300 V

It (RMS) per AC terminal, terminal temperature<115 ℃ 400 A

IFSM junction temperature Tj=150 ℃, pulse width tp=10ms, sine 180 ° 6900 A

I ² t Tj=150 ℃, tp=10ms (diode) 238 kA ² s

Tstg storage temperature -40~85 ℃

IGBT VCES Tj=25℃ 1200 V

IC Tj=150℃，Ts=25℃ 1145 A

IC Tj=150℃，Ts=70℃ 882 A

ICnom rated current 1200 A

TJ junction temperature (note: -40~150 ℃) -40~150 ℃

Diode VRRM Tj=25 ℃ 1200 V

IF Tj=150℃，Ts=25℃ 925 A

IF Tj=150℃，Ts=70℃ 700 A

IFnom rated forward current 930 A

Tj junction temperature -40~150 ℃

Driver Vs power supply voltage 13~30V

ViH input signal high level voltage 15+0.3 V

VisolPD QPD≤10pC， 1170 V from the primary side to the power end

Dv/dt secondary to primary voltage change rate of 75 kV/μ s

FSW switch frequency 15 kHz

（2） Key characteristic parameters

Category parameter symbol condition description Minimum value Typical value Maximum value Unit

IGBT VCE (sat) IC=600A, Tj=25 ℃ (at the terminal) 1.7-2.1 V

VCE (sat) IC=600A, Tj=125 ℃ (at the terminal) -1.9-V

Eon+Eoff IC=600A，VCC=600V，Tj=125℃ – 221 – mJ

Eon+Eoff IC=600A，VCC=900V，Tj=125℃ – 390 – mJ

Rth (j-s) each IGBT switch, junction to heat sink thermal resistance -0.03 K/W

Diode VF (VEC) IF=600A, Tj=25 ℃ (at the terminal) 1.50-1.80 V

Err IF=600A，VR=600V，Tj=125℃ – 42 – mJ

Err IF=600A，VR=900V，Tj=125℃ – 56 – mJ

Rth (j-s) each diode switch, junction to heat sink thermal resistance -0.058 K/W

Driver Is current formula: 240+k1fsw+k2IAC (k1=29mA/kHz, k2=0.00065mA/A ²) — mA

ITRIPSC overcurrent trip level 1470 1500 1530 A (peak)

Tttrip over temperature trip level 110 115 120 ℃

System Rth (r-a) flow rate=460m ³/h, Ta=25 ℃, altitude 500m -0.0344 K/W

LCE commutation inductor -6- nH

W Weight without heat sink -1.7kg

WH heat sink weight -4.4kg

Isolation and environmental requirements

（1） Isolation coordination (compliant with EN 50178 and IEC 61800-5-1)

Grid voltage: The maximum RMS value of the grounding triangle grid line voltage is 480V+20%, corresponding to an installation altitude of 2000m; the maximum RMS value of the star point grounding grid line voltage is 480V+20%, corresponding to an installation altitude of 5000m;

Transient voltage: The maximum transient peak voltage between the low-voltage circuit and the power grid is 1600V;

Protection level: The heat sink is basically isolated from the power grid, with a protection level of IP00 (compliant with IEC 60529);

Pollution level: molded power part external pollution level 2 (compliant with IEC 60664-1);

Overvoltage category: Grid side overvoltage category III (compliant with IEC 60664-1).

（2） Environmental conditions (compliant with IEC 60721)

Environmental scenario, climate conditions, biological conditions, chemical active substances (excluding salt spray), mechanical active substances, mechanical conditions, pollution of fluids

Storage: 1K2 1B1 1C2 1S1 1M3 (customer customized packaging without declaration)-

Transport 2K2 (extended temperature range -40~85 ℃, shortened operating life near 85 ℃) 2B1 2C1 2S1–

Weather protection fixed use 3K3/1 3B1 3C2 3S1 3M6 (3M7 is feasible but limited by external components)-

Ground installation operation 5K1m 5B1 5C2 5S1 5M3 (no foreign objects/stone impact) 5F1

Ship Environment Operation -6B1 6C2 6S1 6M3-

Other key information

Thermal characteristic chart: including IGBT/diode output characteristics, energy loss (E=f (Ic, VCC)), flow rate and voltage drop/thermal resistance relationship, transient thermal impedance and other charts (as shown in Figure 1-9), which can be used for thermal design and loss calculation;

Mechanical dimensions: Provide detailed installation dimensions for modules and heat sinks (such as bolt specifications M4/M5/M6/M8, installation depth, spacing, etc.), which need to be mechanically assembled according to the drawing parameters;

Electrostatic sensitivity: It belongs to electrostatic discharge sensitive devices (ESDS) and should be operated in accordance with the specifications in Chapter 9 of IEC 60747-1;

Usage tip: Component specifications do not represent feature guarantees, and specific application testing is required; Prior written approval from SEMIKRON is required for use in life support equipment, and it is recommended to consult the manufacturer before use.

Module Core Overview

Bently Nevada’s 3500/60 and 3500/61 temperature modules both have 6-channel temperature monitoring capabilities and are compatible with resistance temperature detectors (RTDs) and thermocouples (TCs) inputs. They can condition input signals and compare them with user programmable alarm thresholds. The core functions of the two are the same, the only difference being that the 3500/61 provides recorder outputs for each of the six channels, while the 3500/60 does not have this function.

The module needs to be set to RTD or TC measurement mode through the 3500 rack configuration software, providing multiple I/O module versions:

RTD/TC non isolated version: can be flexibly configured to receive only TC, only RTD, or a combination of both inputs;

TC Isolation Edition: Equipped with 250Vdc inter channel isolation capability, it can resist external interference.

In the Triple Modular Redundancy (TMR) configuration, three temperature monitors need to be installed adjacent to each other, and the system ensures operational accuracy through two voting mechanisms to avoid single point failures.

Key technical parameters

Measurement range: TC (Type J/K/T/E, Range reduction at high temperature for Type E); RTD (made of platinum/nickel/copper material, with some parts having a narrower range after external barriers, platinum RTD (α=0.00385) is an industry standard).

Output and accuracy: The front panel has OK/TX/RX/Bypass LEDs; RTD current source 925 ± 15 μ A (25 ℃); Temperature resolution of 1 ℃/℉, accuracy of ± 1-3 ℃ (depending on configuration), alarm accuracy of ± 0.13%, supporting warning (1-60 second step size of 1 second), danger (1-60 second step size of 0.5 seconds) delay.

Environment and size: working temperature 0-65 ℃ (with internal barriers), storage temperature -40-85 ℃; Monitor module 241.3 × 24.4 × 241.8mm (0.91kg), with slightly smaller I/O module size/weight, each occupying one full height slot.

Compliance and Ordering

Certification: Compliant with FCC, EMC (2014/30/EU), RoHS, IEC 62443 network security, up to SIL 2, certified for hazardous areas such as CSA/ATEX (with or without internal barriers).

Order: Both 3500/60 (without recorder) and 3500/61 (with recorder) are “Model – AA (I/O type) – BB (certified)”, with accessories including terminal blocks, cables of different lengths (assembled/unassembled), and specialized spare parts.

Ordering and accessory information

（1） Module Ordering Model

3500/60 (without recorder output): Model format 3500/60-AA-BB

AA (I/O module type): 01 (RTD/TC non isolated internal terminal), 02 (RTD/TC non isolated external terminal), 03 (TC isolated internal terminal), 04 (TC isolated external terminal), 05 (RTD/TC non isolated with internal barrier)

BB (Institutional Certification Options): 00 (No Certification), 01 (CSA/NRTL/C, Class I, Zone 2), 02 (ATEX/IECEx/CSA, Class I, Zone 2)

3500/61 (with recorder output): Model format 3500/61-AA-BB, AA and BB options have the same meaning as 3500/60

（2） External terminal block

Model Description

133908-01 RTD/TC non isolated external terminal block (terminal block connector)

133916-01 RTD/TC non isolated external terminal block (European connector)

133924-01 TC Isolation External Terminal Block (Terminal Block Connector)

133932-01 TC isolated external terminal block (European connector)

133892-01 3300/61 Recorder Output External Terminal Block (Terminal Block Connector)

133900-01 3300/61 Recorder output external terminal block (European connector)

（3） Cable

3500/60 and 3500/61 sensors (XDCR) signal to external terminal (ET) block cable: model 134544-AAAA-BB

AAAA (length): 0005 (5 feet/1.5 meters), 0007 (7 feet/2.1 meters), 0010 (10 feet/3.0 meters), 0025 (25 feet/7.5 meters), 0050 (50 feet/15 meters), 0100 (100 feet/30.5 meters)

BB (assembly instructions): 01 (unassembled), 02 (assembled)

3500/61 recorder output to external terminal (ET) block cable: model 134543-AAAA-BB, AAAA (length) option is the same as the above cable, BB (assembly instructions) 01 (not assembled), 02 (assembled), and the recorder cable is not used for/60 or/62 monitors

（4） Spare parts

3500/60 and 3500/61 share spare parts: including various external terminal blocks, connector plugs (such as 00580442: 9-position green internal terminal connector plug), 3500/60&61 user guides (134542), etc

3500/60 specialized spare parts: such as 163179-01 (3500/60 temperature monitor, no recorder), 133827-01 (3500/60 RTD/TC non isolated external terminal I/O module), etc

3500/61 specialized spare parts: such as 163179-02 (3500/61 temperature monitor with recorder), 133819-02 (3500/61 RTD/TC non isolated internal terminal I/O module), etc

Product classification and structural design

The ACS880 series is divided into three categories based on installation method and power range, suitable for different industrial environment requirements:

Structure type, power range, typical application scenarios, core characteristics

Wall mounted (Type 01) 0.55kW-75kW small and medium power single machine control (such as fans, water pumps, conveyor belts) with compact size, IP21 protection (preventing vertical dripping and solid foreign objects), natural cooling or forced air cooling, suitable for installation in control cabinets/dry environments

Cabinet style (04/06 type) 11kW-2800kW high-power or complex control (such as rolling mill, compressor, centrifuge) independent cabinet design, IP21/IP54 protection optional, built-in cooling system (air-cooled/water-cooled), integrated input circuit breaker, reactor and other accessories, supports multi machine linkage

Modular (02 type) 160kW-2800kW ultra high power scenarios (such as mine hoists, large fans) modular components (power modules, control units, auxiliary modules) that need to be matched with user made cabinets, support redundant design, and adapt to customized systems

Electrical performance and speed regulation capability

The manual specifies the series of general electrical parameters, and the differences between different models are distinguished by the “model suffix” (such as voltage level, power code):

Input voltage range:

Low voltage series: 200-240V AC (single-phase/three-phase), 380-480V AC (three-phase), 500-690V AC (three-phase), all supporting ± 10% voltage fluctuation;

Frequency adaptation: 50/60Hz (± 5% fluctuation), compatible with global grid frequencies.

Output performance:

Output frequency: 0-500Hz (standard), 0-1000Hz (high frequency optional), supporting high-speed motor speed regulation;

Speed control accuracy: open-loop V/F control ± 0.5% rated speed, closed-loop vector control ± 0.1% rated speed;

Starting torque: 150% rated torque @ 0Hz under vector control (suitable for heavy-duty starting, such as crushers and extruders).

Control mode:

Basic mode: V/F control (square torque/constant torque curve optional, suitable for loads such as fans and pumps);

Advanced modes: sensorless vector control (no encoder required, suitable for scenarios without position feedback), closed-loop vector control (with encoder, high-precision speed regulation), torque control (constant torque output, such as curling equipment);

Special functions: synchronous control (multi motor speed/torque synchronization), process PID control (built-in PID regulator, directly related to process parameters such as pressure and flow), energy-saving mode (automatic optimization of voltage frequency ratio, reducing no-load losses).

Safety and protection functions

The manual emphasizes the safety design of the series, which complies with international safety standards such as IEC 61800-5-1. The core protection functions include:

Motor protection: overcurrent, overload (inverse time characteristic), locked rotor, phase loss, over temperature (supporting motor PTC thermistor connection), insulation monitoring;

Inverter protection: DC bus overvoltage/undervoltage, IGBT module overheating, input phase loss, output short circuit, ground fault (optional residual current detection), lightning surge protection;

System safety: Safe torque shutdown (STO, SIL2 certification, cutting off motor torque output in emergency situations), safe stop (SS1/SS2, compliant with EN ISO 13850), adapted to industrial safety circuit design.

Communication and integration capabilities

The ACS880 series supports multi protocol communication, making it easy to connect to PLC, DCS, or upper computer systems. The manual provides detailed instructions on the configuration methods for each protocol

Standard communication: RS485 interface (supporting Modbus RTU protocol), used for local small-scale communication;

Optional modules: Profinet, EtherNet/IP, DeviceNet, CANopen, Profibus DP and other industrial Ethernet modules to achieve high-speed remote monitoring and multi device linkage;

ABB exclusive protocol: Supports ABB DriveBus and can quickly network with ABB PLC (such as AC500) or other ACS880 frequency converters, simplifying synchronous control configuration.

Manual Key Operation Guide (Installation, Debugging, and Maintenance)

1. Installation and wiring specifications

The manual specifies the prerequisites for safe installation (such as power-off operation, electrostatic protection) and core steps:

Installation environment requirements: working temperature -25~40 ℃ (some models can be extended to -40~50 ℃), relative humidity 5% -95% (no condensation), altitude ≤ 1000m (reduced capacity is required for use at high altitudes), away from dust, corrosive gases, and strong electromagnetic interference sources;

Wiring points:

The main circuit (input L1/L2/L3, output U/V/W) needs to match the cross-sectional area of the wires (according to the rated current), and install input circuit breakers and reactors (to suppress harmonics, optional);

Shielded wires are required for control circuits (analog I/O, digital I/O, encoder interfaces), with the shielding layer grounded at one end to avoid parallel laying with the main circuit cable (reducing interference);

The safety circuit (STO, emergency stop) needs to be independently wired to ensure that protection is triggered first in case of a fault.

2. Debugging process and parameter configuration

The manual provides standardized debugging steps, suitable for most application scenarios:

Pre power on inspection: Confirm correct wiring (no short circuit, virtual connection), grounding resistance ≤ 4 Ω, parameter reset (default factory settings);

First power on: first turn on the control power supply (check if the panel display is normal), then turn on the main power supply (continue only if there are no fault alarms);

Motor identification: Implement the “motor identification” function (static/dynamic identification optional), the frequency converter automatically reads motor parameters (such as rated power, current, impedance), and optimizes control accuracy;

Core parameter settings: Configure key parameters based on load characteristics (such as control mode P100, rated speed P304, starting torque P640, acceleration/deceleration time P221/P222);

Trial operation: First, jog the motor to test the direction of rotation (to avoid equipment damage caused by reverse rotation), then gradually increase the speed to the rated value, and monitor whether the current and temperature are normal.

3. Fault diagnosis and maintenance

The manual includes a “fault code table” that details the causes and troubleshooting methods of common faults (such as F001 overcurrent, F002 overvoltage, F003 overheating), and provides maintenance recommendations:

Daily maintenance: Clean the heat dissipation channel (dust screen, heat sink) weekly, check the tightness of the wiring terminals monthly, and check the insulation resistance quarterly (main circuit to ground ≥ 1M Ω);

Regularly replace components: cooling fan (with a lifespan of about 2-3 years), electrolytic capacitor (with a lifespan of about 5-8 years, adjusted according to the ambient temperature). The manual specifies the vulnerable part models and replacement steps for different models;

Fault record: The frequency converter can store the last 20 fault information (including fault time, current/voltage/speed at the time of the fault), which can be read through the panel or communication interface to assist in locating the root cause.

The Emerson DeltaV S-series traditional I/O module is a modular input/output subsystem designed specifically for DeltaV distributed control systems (DCS). Its core positioning is to enhance the flexibility, reliability, and installation and operation efficiency of industrial process control. It is suitable for industrial scenarios such as petrochemicals, electricity, and energy that require high environmental adaptability and system stability. It can achieve precise acquisition and output of analog and discrete signals.

Core Features and Advantages

Modular and flexible architecture

Scalable design: A single controller can support up to 8 I/O carriers, with a total of 64 I/O slots. It supports mixing various I/O modules such as analog (AI/AO) and discrete (DI/DO) to meet the signal acquisition and control needs of different scenarios.

On demand configuration: Supports the “on-demand procurement” mode, allowing for the selection of I/O cards, 8-slot carriers, power supplies/controllers, and other components based on the system size. These components can be flexibly added as the system expands, avoiding resource waste.

Efficient installation and maintenance

Tool free installation: The carrier is fixed to the T-shaped DIN rail through a buckle, and the I/O module is directly inserted into the slot without the need for tools; All wiring is completed through carriers and terminal blocks, and there is no need to disconnect on-site wiring when replacing modules, reducing maintenance downtime.

Error proof design: Each I/O module and terminal block is equipped with a dedicated “key positioning” mechanism (two rotatable positioning columns, 6 position combinations), allowing only matching modules to be inserted into the corresponding terminal block to avoid the risk of incorrect installation.

Integrated power supply: The I/O carrier is equipped with a 24V DC bus based on-site power distribution, which is divided into primary/secondary power supplies for odd/even slots. Each slot is independently protected by a fuse, reducing the design of external power supply circuits and ensuring that single card failures do not affect other modules.

Online Expansion and High Availability

Online expansion: Supports adding I/O carriers with power on (directly connected to the right side of existing carriers or installed on other DIN rails through extension cables). The controller automatically detects new carriers and modules and enters them into the configuration database without interrupting existing I/O communication.

1: 1. Redundant backup: 4 types of critical I/O cards (such as 8-channel AI/AO, 32 channel DI/DO) support redundant configuration, and can be automatically recognized as redundant pairs by the system when installed in pairs on redundant terminal blocks. In the event of a fault, the switching can be completed within 2 I/O bus scanning cycles (signal overlap<5ms during analog switching, and digital “first on, then off” to ensure uninterrupted power supply to the device), without the need for additional configuration.

Adaptability to harsh environments

Wide temperature operation: All I/O modules operate within a temperature range of -40~70 ℃ (-40~158 ℉) and can be installed in on-site cabinets to reduce the control room footprint and shorten the length of multi-core cable wiring, thereby lowering costs.

Anti interference and anti-corrosion: Complies with ISA-S71.04-1985 G3 level anti-corrosion standard (using normal coating), anti impact (10g half sine wave, 11ms), anti vibration (1mm peak to peak value at 5-13.2Hz, 0.7g at 13.2-150Hz), suitable for complex electromagnetic and environmental interference in industrial sites.

Core product composition and I/O module classification

1. Subsystem composition

The traditional I/O subsystem of DeltaV S-series mainly includes the following components:

I/O carrier: DIN rail installation, carrying all I/O components, providing bus power supply and communication interfaces, divided into 8 slot horizontal carriers and other types.

Power supply: Large capacity AC to 24V DC power supply, providing power for on-site equipment and I/O modules.

I/O module: including analog input/output, discrete input/output and other types, all of which adopt a unified appearance design and are used with dedicated terminal blocks.

Auxiliary accessories: Cable extender (flexible adjustment of carrier installation position), terminal block (standard/fused/redundant type), Mass connection module (compatible with third-party wiring schemes).

2. I/O module types and key parameters

The modules are divided into two categories: analog (AI/AO) and discrete (DI/DO), and support simplex (single-mode) or redundant (redundant) installation. The following are the core module specifications:

(1) Analog input (AI) module

Module type, channel number, signal type, key parameters

AI 4-20mA HART 8 4-20mA (2/4 wire system) resolution 16 bits, accuracy of 0.1% range at 25 ℃, channel optical isolation 1500V DC, supporting HART transparent transmission (scan time 600-800ms/channel)

AI Plus 4-20mA HART 16 4-20mA (2/4-wire system) resolution 16 bits, accuracy 0.2% range, channel optical isolation 1000V DC, supports Mass terminal block and fault detection

RTD module 8 Pt100/Pt200/Ni120 2/3/4 wire system, excitation current 100 μ A, Pt100 measurement range -200~850 ℃, accuracy ± 0.5 ℃ (25 ℃)

Thermocouple/mV module 8 B/E/J/K/N/R/S/T type thermocouple, mV signal cold end compensation ± 1 ℃, mV range -100~100mV, accuracy ± 0.1mV (25 ℃)

Isolation type AI module 4 thermocouples/mV/V/RTD channel optical isolation 1500V DC, supports wide range voltage signals (0-5V/0-10V, etc.), and improves accuracy (such as E-type thermocouples ± 0.5 ℃)

(2) Analog Output (AO) Module

Module type, channel number, signal type, key parameters

AO 4-20mA HART 8 4-20mA resolution 14 bits, -40~60 ℃ accuracy 0.25% range, channel optical isolation 1500V DC, supports open circuit detection (<0.7mA)

AO Plus 4-20mA HART 16 4-20mA resolution 14 bits, accuracy 0.25% range, channel optical isolation 1000V DC, supports Mass terminal block, maximum on-site power supply 400mA@24V  DC

(3) Discrete Input (DI) module

Module type, channel number, signal type, key parameters

DI 24V DC dry contact 8 dry contact (compatible with NAMUR sensor) with conductivity detection>2.2mA, shutdown<1mA, input impedance 5k Ω, channel optical isolation 1500V DC

DI Plus 24V DC dry contact 32 24V DC dry contact conductivity detection>2mA, shutdown<0.25mA, supports terminal fault detection (requires Mass terminal block), on-site power supply 150mA@24V  DC

Pulse Counting Input (PCI) 4 24V DC frequency range 0.1Hz~50kHz, minimum pulse width 10 μ s, 32-bit unsigned counter, channel optically isolated 1500V DC

Sequence of Events (SOE) input 16 24V DC dry contact channel scan rate 0.25ms/16 channels, timestamp accuracy ± 0.25ms (single card)/± 1ms (single controller), supports event logging

DI 120V AC isolation type 8 120V AC conduction detection 84~130V AC, turn off 0~34V AC, input impedance 60k Ω, channel to channel optical isolation 250V AC

(4) Discrete Output (DO) module

Module type, channel number, signal type, key parameters

DO 24V DC high side 8 24V DC maximum 1A continuous output per channel (surge 4A<100ms), turn off leakage<1.2mA, channel optical isolation 1500V DC

DO Plus 24V DC high side 32 24V DC output of 100mA per channel, cut-off leakage<0.1mA, supports terminal fault detection, on-site power supply 3.2A@24V  DC

DO 120/230V AC isolation type 8 120/230V AC maximum 1A continuous output per channel (surge 5A<100ms), turn off leakage 2mA (120V AC)/4mA (230V AC), channel to channel optical isolation 250V AC

Terminal block and system compatibility

1. Terminal block type and adaptation

Terminal blocks are divided into standard terminal blocks, fuse terminal blocks, redundant terminal blocks, and Mass terminal blocks. Different I/O modules require dedicated terminal blocks, and the core adaptation relationship is as follows:

Example features of terminal block type adaptation module

8-channel standard terminal block, 8-channel AI/AO, 8-channel DI/DO basic wiring, supporting single-mode installation

8-channel fuse terminal block. All 8-channel modules are equipped with 2A fuses to protect the on-site circuit

Redundant 8-channel terminal block with 8-channel redundant AI/AO and DI/DO supports parallel installation of 2 modules to achieve redundant backup

Mass terminal block (16/24/40/48 pins) Plus series modules, some standard modules are compatible with S-series Mass connection solutions or third-party devices (such as Pepperl+Fuchs HiC safety barriers), optimizing on-site wiring

2. System compatibility requirements

Controller: SQ or SX series controllers are required, and V11.3.1 and above versions of the DeltaV system support S-series and M-series controllers running on the same network.

Software version: The Plus series modules (16 channel AI/AO, 32 channel DI/DO) require DeltaV v13.3 or higher.

Installation restrictions: only supports horizontal carriers, not compatible with vertical carriers; Vertical I/O applications require the use of CHARMS electronic grouping I/O.

Certification and Security Standards

International certification:

Electrical safety: CE (EN 61326-1), FM (3600/3611), CSA (C22.2 No.213/1010-1).

Explosion proof certification: ATEX（II 3G Ex ec IIC T4 Gc）、IECEx（II 3G Ex ec IIC T4 Gc）、FM/CSA Class I, Division 2（Groups A-D, T4）。

Classification certification: IACS E10, ABS design evaluation certificate, DNV marine certificate.

Safety design:

Isolation protection: All module channels are optically isolated from the system (1000~1500V DC), and some discrete module channels are additionally isolated from each other.

Fault alarm: Hardware faults (such as module failure, communication interruption, on-site wiring failure) automatically trigger system alarms, with logs recorded in the Event Chronicle, and support for real-time viewing of module status on the diagnostic interface.

Order

1. Core module ordering model (example)

Module Description Model Example

8-channel AI 4-20mA HART (with AI 8-channel terminal block) SE4003S2B1

16 channel AO Plus 4-20mA HART (with 48 pin Mass terminal block) SE4005S2B5

32 channel DI Plus 24V DC (with redundant 40 pin Mass terminal block) SE4081S2T2B7

8-channel DO 120/230V AC isolated type (with fuse terminal block) SE4002S2T1B2

The Honeywell MVCweb control system is a programmable building automation controller based on open standards (belonging to the Honeywell EXCEL 5000 open system). Its core positioning is to reduce the full lifecycle cost of buildings, while supporting multi scenario building management functions. It has flexible communication compatibility, remote operation and maintenance capabilities, and high reliability, and is suitable for HVAC（ heating, ventilation, and air conditioning， heating, ventilation, and air conditioning）、 Building automation scenarios such as energy management and lighting control.

Core Features and Advantages

Cost optimization design

Hardware cost: Reuse existing Ethernet/LAN infrastructure to reduce communication cabling investment; Supports flexible selection of onboard I/O and Panel Bus I/O to avoid redundant configurations.

Operation and maintenance costs: No need to separately maintain the operator interface software (software integrated into the controller, following the “single source principle”); Support remote browser access to reduce on-site operation and maintenance frequency.

Open compatibility and multi protocol support

Communication standard: Fully compatible with international mainstream building communication protocols, including BACnet/IP（ISO 16484-5）、BACnet MS/TP（ISO 16484-5）、LONWORKS（ISO 14908）、Modbus RTU Master、M-Bus（EN 1434-3）， Seamless integration with third-party BACnet devices and Honeywell front-end systems (such as Enterprise Buildings integrator) ™、 SymmetrE and LONWorks devices.

Manufacturer independence: Based on open protocol design, there is no need to rely on a single supplier, reducing the limitations of system upgrades and extensions.

Flexible operation and monitoring

Remote access: Built in web server, supports local/remote operation on any networked PC (laptop, desktop, touch screen) through standard browsers (IE 9.0. x, Mozilla Firefox 15.0. x, etc.), compatible with WIN CE system 320×240 pixel touch screen (such as Excel Touch).

Data Trend and Alarm: Supports trend recording for 100 data points; The built-in email/SMS alarm function can send the alarm information to the mailbox or mobile phone through the network or Internet DSL connection, and the alarm rules can be customized.

High reliability and security guarantee

Stable operation: It is equipped with an embedded LINUX system to ensure an independent and safe operating environment, especially suitable for scenarios requiring access to the Internet.

Network security: it needs to be deployed on a private network (such as VPN) or isolated from the Internet through an external firewall; Support 6 levels of user permission management, each level can be configured with independent read and write permissions and passwords to prevent unauthorized operations.

Fault Monitoring: Equipped with M-Bus and Modbus slave device communication fault detection functions, it can automatically retry communication and mark fault status to ensure data collection continuity.

Core functions and technical parameters

1. Control and application capabilities

Function category details

Application scenarios include HVAC control (such as optimal start stop, nighttime purification, maximum load demand control), lighting monitoring, shading control, heat/energy metering, etc

Control performance supports 4 levels of optional control loop priority (multitasking), optional control loop cycle time, event driven switching table, and adapts to the control accuracy requirements of different scenarios

The programming tool allows for free programming through graphical CARE engineering tools, supports existing applications and macro instruction reuse, and has online debugging capabilities

2. Communication interface and parameters

(1) Main communication interface configuration

Number/specifications of interface types, supported protocols/functions, maximum transmission distance

Ethernet (RJ45) 1 10/100 Mbit/s, BACnet/IP communication, browser access, FTP firmware download 100m

RS485 2 (1 isolated, 1 non isolated) BACnet MS/TP, Panel Bus, Modbus RTU Master (only 1 interface can be used simultaneously) 1000m (depending on baud rate)

RS232 (RJ45) 1 M-Bus communication (requires PW3/PW20/PW60 converter), factory debugging 350m (M-Bus)

USB 2.0 2 (1 Host, 1 Device) Host: Connect IF-LON interface (maximum 500mA); Device: Connect CARE tool, touch screen 3m

1 HMI interface (some models) with built-in LCD display screen (5 lines x 20 characters), 6 operation keys, and 1 rotary press key; Some models support external MVC-2000HMI-A 5m (external HMI)

(2) Key communication protocol parameters

M-Bus: Supports 300/2400/9600 Baud, connects up to 60 slave devices, configurable measurement cycle (1-7 days), slave device address range 1-250.

Modbus RTU Master: supports 9.6-115.2 kBaud, can connect up to 32 slave devices, with an address range of 1-247; Supports 16/32-bit registers, with data types including BOOL, INT16/UINT16, INT32/UINT32, FLOAT; Support CRC frame check, 1-2 stop bits, optional parity check (none/odd/even).

LONWorks: Requires IF-LON interface (FTT-10A/FT-X1 transceiver), communication rate of 78 Kbaud, maximum cable length of 320-2200m (depending on topology).

3. Environmental and electrical parameters

Parameter category specification

Working temperature wall mounted installation: 0-40 ℃; Cabinet interior/cabinet door installation: 0-50 ℃

Storage temperature -20-70 ℃

Relative humidity 5% -95% (no condensation)

Protection level wall mounted (with MVC-80-AC1 cover): IP20; Cabinet door installation (with MVC-80-AC2): IP30

Power supply 19-29 VAC (50/60Hz) or 20-30 VDC

Power consumption DC: typical 5W, maximum 6W; AC: typical 9VA, maximum 11VA

CPU and Memory: ARM 9 32-bit processor (450 MHz); 128 MB DDR2-RAM，1 GB Flash Memory

Model classification and hardware configuration

The MVCweb series includes three core models, with main differences in onboard I/O quantity, HMI configuration, and external HMI support capability. The total I/O quantity includes onboard I/O, Panel Bus I/O, and LONWorks Bus I/O.

Model, onboard I/O quantity, total I/O quantity, HMI configuration, external HMI support

MVC-WEB-2014B2B 14 with 52 built-in HMIs (LCD+buttons) not supported

MVC-WEB-2026B2A with 26 built-in HMIs (LCD+buttons) and 600 built-in HMIs is not supported

MVC-WEB-2026B3A 26, 600 without built-in HMI support (including RJ45 interface, can be connected to MVC-2000HMI-A)

Typical I/O types and specifications (taking 26 onboard I/O as an example)

Analog Input (AI): Supports NTC20k temperature sensor, 0-10V signal, maximum transmission distance of 400m.

Digital Input (DI): Supports 24V open circuit/2.0mA closed signal, total counting frequency 15Hz, maximum transmission distance 400m.

Analog output (AO): 0-11V signal (maximum 1mA), maximum transmission distance 400m.

Digital output (DO): Relay normally open contacts (including high surge current type), maximum transmission distance of 400m.

Installation and usage precautions

Wiring requirements

M-Bus/Modbus: Shielded twisted pair cable (J-Y – (St) – Y 2 × 2 × 0.8) is required, with the shielding layer grounded at one end; Modbus only supports daisy chain topology, with branch lengths not exceeding 20m.

Power isolation: It is prohibited to share transformer power supply with other controllers/devices (such as PW M-Bus adapters) to avoid interference.

Electrostatic protection: During installation, it is necessary to follow the rules for electrostatic discharge protection to avoid damaging the equipment.

Accessories and Selection

Essential accessories: detachable terminal plug (TPU-45-01), terminal cover (MVC-80-AC1), cabinet door installation accessories (MVC-80-AC2), strain relief (MVC-40-AC3), etc. (to be purchased separately).

Signal conversion: If you need to convert a 0-20mA signal to 0-10VDC, you can use the auxiliary terminal pack (XS831).

Compliance and Certification

Compliant with multiple international standards: BTL, AMEV AS-A, EN 60730-1/2-9, UL60730, UL916, as well as Ethernet IEEE 802.3, BACnet ANSI/ASHRAE 135-2010.

Document reference: Follow the product manual (EN1B-0567GE51), protocol conformity statement (EN0B-0716GE51), and network security white paper (EN2B-0398GE51).